NEBOSH International Diploma

Transcription

1 NEBOSH International Diploma UNIT IC International Management of Hazardous Agents in the Workplace Sample Trainer Pack

2 RRC Trainer Packs are designed to aid delivery of face-to-face, or classroom-taught, courses by tutors approved by the relevant awarding body (e.g. NEBOSH, IOSH, IEMA).The full pack of which this is a sample includes the following resources: An electronic copy of the RRC student textbook (course notes) for the course, supplied for use by the tutor as reference only. A helicopter plan (MS Word) an overview of how the course will be delivered over its duration. Daily lesson plans (MS Word) a suggested breakdown of how the detailed subjects specified in the qualification syllabus will be covered on each day of the course Slides (MS PowerPoint) full-colour slides addressing the subjects specified in, and following the structure of, the qualification syllabus. Depending on the course, some Packs also contain additional resources, to be used at the tutor s discretion. Some third-party resources may be suggested in the Lesson Plans, or in the notes to the slides for example, video footage, further reading, etc. These are not essential and they are not included as part of the licensed Trainer Pack it is up to the tutor to source the suggested material, should he or she wish to do so. This Sample Trainer Pack contains a selection of pages from a lesson plan, a number of corresponding slides, and the relevant pages from the course textbook. These pages and slides are representative of the presentation, design and language of the full materials. If you like what you see and wish to order a complete Trainer Pack for the course you want to deliver, please contact RRC s customer advisors on , or info@rrc.co.uk

3 LESSON PLAN COURSE: NEBOSH International Diploma, Unit IC LESSON No5: Week 1, Day 5 TITLE: IC5 Work equipment (general) (part 2)/ IC10 Workplace transport and driving for work Timings Subjects to be covered Activities and Aids Group Feedback: review answers to questions from previous evening Approx minutes coffee break DPS (get students to take turns in scribing some answers on flip chart) IC5 Work equipment (general) Maintenance and Inspection Review of the hazards and precautions associated with the maintenance of work equipment. Explanation of planned preventive; condition based; and breakdown maintenance Brainstorm the factors to be considered in developing a planned maintenance programme for safety-critical components on Flip Chart. Identify the requirements for the maintenance of work equipment, including hired work equipment. Discussion on the factors to be considered in determining inspection regimes for equipment and the need for functional testing of safetyrelated parts Competence, Training, Information and Supervision Individual/Small Group exercise 10: In groups of 2 or 3 to tackle selected exam questions relevant to topics being discussed. Whole group feedback using flipchart/whiteboard as focus. Library resources: The Safety Assessment Federation Guidance document MLCC05 - In-Service Inspection Procedures - Information on human factors, training and competence:

4 Clarification of the terms competence and training The relationship between competence, external (imposed) and selfsupervision (diagram from HSG65) Individual/Small Group exercise Lunch Approx minutes coffee break IC10 Workplace transport and driving for work Workplace transport operations Directed Q & A and discussion on loss of vehicle control Review of non-movement related hazards; loading, unloading and securing loads; sheeting; coupling; and vehicle maintenance work. Outline of control measures for safe workplace transport operations Driving at work Discussion of the extent of work related road injuries and fatalities. Brainstorm the factors associated with driving at work that increase the risk of being involved in a road traffic incident Explanation of the evaluation of the risks of road related injuries/fatalities and the risk factors associated with the driver, the vehicle and the journey Application of the control measures to reduce work related driving risks Individual/Small Group exercise 11 Individual/Small Group exercise 11: In groups of 2 or 3 chose a familiar example of driving at work and carry out a risk evaluation with recommendations for control measures. Individual group feedback using flipchart/whiteboard as focus. Library resources: HSG136 Workplace transport safety An employers guide INDG382 Driving at work, Managing work-related road safety Safety issues of vehicle maintenance work: HSG261 Health and safety in motor vehicle repair

5 NEBOSH International Diploma Environmental Element IC7: Work Equipment (Mobile, Lifting and Access Diploma

6 Element IC7 1. Mobile Work Equipment: Hazards and Control Measures 2. Lifting Equipment: Hazards and Control Measures 3. Access and Work at Height Equipment: Hazards and Control Measures

7 Applications of Different Types of Mobile Work Equipment Self-propelled mobile work equipment is work equipment which is propelled by its own motor or mechanism. Towed mobile work equipment includes work equipment such as towed machines and trailers which are primarily self-supporting on their own wheels. Attachments are work equipment which may be mounted on selfpropelled mobile work equipment to alter its characteristics. Pedestrian-controlled work equipment is operated by a pedestrian via a control handle. Remote-controlled mobile work equipment is operated by controls which are not physically connected to it such as radio control.

8 Counterbalance: Types of Lift Truck The mass of a counterbalanced lift truck acts as a counterweight so that the load can be lifted and moved without the truck tipping. Reach: When the forks are extended, the reach truck behaves in a similar manner to the counterbalance. Rough terrain: These are designed to operate on uneven surfaces such as those encountered on construction sites. Telescopic materials handlers: These trucks operate up to a height of 12 metres in narrow aisles. Side loading: A type of reach truck used to carry long lengths of timber. Pedestrian-controlled: These are operated by a pedestrian via a control handle.

9 Types of Lift Truck

10 Other Types of Mobile Work Equipment Agricultural Tractors Used for pulling machinery or trailers for activities such as ploughing, tilling, disking, harrowing, planting, and similar tasks. Works Vehicles Include any vehicles that are used in a work setting such as forklift trucks, compact dumpers, tractors or mobile cranes. They can also include cars, vans and large goods vehicles when these are operating off the public highway.

11 The Hazards Associated with Mobile Work Equipment Lift Truck Hazards are associated with: The truck: Hazards arise from poor maintenance of brakes, steering, tyres, lights, etc., and emission of substances while being used, i.e. exhaust gases. The operator: Driving too fast and cornering at speed can cause the vehicle to overturn or lose its load. The operation: Lift trucks are often used in areas where there is a possibility of impact with people as well as with structures such as walls and racking. Overloading of lift trucks can lead to loss of control in steering and braking. Driving over unsuitable ground can cause the load to shift or fall off.

12 The Hazards Associated with Mobile Work Equipment Under certain conditions there may be a risk of roll-over of mobile work equipment while it is travelling. This can involve roll over onto its side or end (i.e. through 90 degrees) or turn over completely (i.e. through 180 degrees or more). The risk will depend on: The nature of the mobile work equipment and any attachments or accessories fitted to it. The effects of any work being carried out on or by the mobile work equipment. The conditions in which it is used.

13 Stability of Vehicles Factors Affecting Lateral and Longitudinal Instability and Loss of Control of Vehicles Instability is a major problem in safe use of vehicles. There are three main ways in which a vehicle may become unstable: Lateral instability vehicle will tip over onto its side. E.g. a lorry is blown over in a high wind, or a loaded forklift tips while driving across a slope. Longitudinal instability vehicle tips over the front or the back. E.g. a tractor s front wheels lift due to nose weight of a trailer. Loss of control wheels lose grip on a road surface. E.g. skidding on an icy road. N.B. loss of control does not require vehicle to overturn.

14 We need to understand the principle of moments. It is the turning effect created by the product of load multiplied by distance, i.e. load distance. For no moments to be exerted on a piece of equipment, the moments should balance. Basic Physics Loading of a Forklift Truck

15 WORK EQUIPMENT (MOBILE, LIFTING AND ACCESS) LEARNING OUTCOMES On completion of this element, you should be able to demonstrate understanding of the content through the application of knowledge to familiar and unfamiliar situations and the critical analysis and evaluation of information presented in both quantitative and qualitative forms. In particular, you should be able to: Unit IC Element IC7: Work Equipment (Mobile, Lifting and Access) 7-1 ELEMENT 7 Describe the main hazards and control measures associated with commonly encountered mobile work equipment. Describe the main hazards and control measures associated with commonly encountered lifting equipment. Describe the main hazards and control measures associated with commonly encountered access equipment and equipment for working at height.

16 Contents MOBILE WORK EQUIPMENT: HAZARDS AND CONTROL MEASURES 7-3 Mobile Work Equipment: Hazards 7-4 Lateral and Longitudinal Instability and Loss of Control of Vehicles 7-10 Mobile Work Equipment: Control Measures 7-11 Revision Questions 7-14 LIFTING EQUIPMENT: HAZARDS AND CONTROL MEASURES 7-15 Lifting Equipment Hazards 7-15 Lifting Equipment Control Measures 7-19 Revision Questions 7-25 ACCESS AND WORK AT HEIGHT EQUIPMENT: HAZARDS AND CONTROL MEASURES 7-26 Access and Work at Height Equipment: Hazards 7-26 Access and Work at Height Equipment: Control Measures 7-28 Revision Questions 7-31 SUMMARY 7-32 EXAM SKILLS Unit IC Element IC7: Work Equipment (Mobile, Lifting and Access)

17 Mobile Work Equipment: Hazards and Control Measures KEY INFORMATION Mobile work equipment is any work equipment which carries out work while it is travelling or which travels between different locations where it is used to carry out work. It can be self-propelled, towed, attached, pedestrian-controlled or remotely-controlled. A common type of mobile work equipment is the lift truck. Types of lift trucks include counterbalance, reach, rough-terrain, telescopic materials handlers, side loading trucks and pedestrian controlled trucks. Lift truck hazards are associated with the: Truck. Operator. Operation. To ensure the safety of mobile work equipment the following issues need to be addressed: Rollover. Overturning. Suitability for carrying passengers. Unauthorised start-up. Safe operating station/platform. Overrun of speed. Contact with wheels and tracks. Falls of objects. Moving parts/drive shafts/power take-offs. Over-heating. The hazards associated with the energising of mobile work equipment may be electrical in connection with battery charging, fire and explosion from LPG, and exhaust fumes and hot surfaces from diesel engines. Lateral and longitudinal instability of mobile work equipment and loss of control of vehicles is a major problem in their safe use. The control measures for the use of mobile work equipment include the need for safe layout of areas where mobile equipment is used and the protection of pedestrians. Where lift trucks are used as working platforms specific safeguards concerning the design, construction and attachment of the platform are necessary. The range of control measures for the use of mobile work equipment includes: Rollover protection. Falling objects protection. Speed control systems. Guards, barriers and restraining systems. Means of fire-fighting. Vision aids. Training of lift truck operators should include: Basic training. Specific job training. Familiarisation training. Unit IC Element IC7: Work Equipment (Mobile, Lifting and Access) 7-3

18 Mobile Work Equipment: Hazards and Control Measures MOBILE WORK EQUIPMENT: HAZARDS GLOSSARY MOBILE WORK EQUIPMENT Any work equipment which carries out work while it is travelling or which travels between different locations where it is used to carry out work. Applications of Different Types of Mobile Work Equipment Mobile work equipment is considered to be any work equipment which carries out work while it is travelling or which travels between different locations where it is used to carry out work. Such equipment would normally be moved on wheels, tracks, rollers or skids. Mobile work equipment may be: Self-Propelled Self-propelled mobile work equipment is work equipment which is propelled by its own motor or mechanism. The motor or mechanism may be powered by energy generated on the mobile work equipment itself, for example by an internal combustion engine, or through connection to a remote power source, such as an electric cable, electric induction or hydraulic line. Towed Towed mobile work equipment includes work equipment such as towed machines and trailers which are primarily self-supporting on, for example, their own wheels. They may have moving parts which: Are powered by the vehicle (e.g. a power harrow). Have an integral power source (e.g. a powered crop sprayer). Have no moving parts and function as a result of the movement of the mobile work equipment (e.g. a plough or trailer). Attached Attachments are work equipment which may be mounted on self-propelled mobile work equipment to alter its characteristics. For example, a load rotator fitted to a forklift truck will alter its load-handling capabilities and may alter its safety characteristics, such as stability. Attachments are not considered to be mobile work equipment in their own right, but if they can affect the safety of the self-propelled mobile work equipment when they are attached, they are considered to be part of the self-propelled work equipment. Attachments may be non-powered, powered by an independent power source or powered by the self-propelled work equipment to which they are attached. Pedestrian-Controlled Pedestrian-controlled mobile work equipment is operated by a person on foot, using controls which are physically connected to the equipment. Examples include pallet trucks and sack barrows, as shown in the picture below. Pedestrian-Controlled Lifting Equipment Remotely-Controlled Remote-controlled mobile work equipment is operated by controls which are not physically connected to it, e.g. by radio control. Types of Lift Truck The transport of materials is an essential feature of many workplace operations and the lift truck provides industry with a versatile materials handling vehicle. In addition to the traditional use of trucks to lift, move and re-stack palletised loads, trucks may be fitted with a variety of attachments including drum-handling equipment, bale clamps, working platforms, skips, fork extensions and lighting appliances, all of which increase the versatility of the vehicle. The following are the most commonly used types of lift truck: Counterbalance The mass of a counterbalance lift truck acts as a counterweight so that the load can be lifted and moved without the truck tipping. However, the truck can be tipped over if: It is overloaded. The load is incorrectly placed on the forks. It is travelling across an incline or an uneven surface. Instability is increased if the truck travels with the forks raised rather than lowered. 7-4 Unit IC Element IC7: Work Equipment (Mobile, Lifting and Access)

19 Mobile Work Equipment: Hazards and Control Measures Counterbalance LPG-powered lift truck Reach When the forks are extended, the reach truck behaves in a similar manner to the counterbalance truck. It is less likely to tip over when the forks are in, as the load is within the wheelbase of the truck, which increases stability. When the load is elevated and the mast tilted back, there is a significant risk of overturning. This risk increases if the load is high and the truck is operating on an uneven surface. Rough-Terrain These trucks are designed to operate on uneven surfaces such as those encountered on construction sites. However, care is needed on rough ground as bouncing can cause loss of control. The trucks should not be used for lifting to high levels unless the ground is reasonably level and consolidated and the truck is clear of excavations and walls. Unless specially designed, they should not be used for stacking on inclines. Telescopic Materials Handlers These trucks operate up to a height of 12 metres. They work in narrow aisles, but can also move outside the aisles. They must operate on high grades of flooring because of the lift height. Some have the operator at ground level, others have a rising cab. They can access the stack on either side of the aisle by using a mast which turns to the left or right (multi-directional). Side Loading Trucks This is a form of forklift truck commonly found in timber yards. It is a type of reach truck used to carry long lengths of timber. Pedestrian-Controlled Trucks These are operated by a pedestrian via a control handle. Operators should always face the direction of travel and not walk backwards nor directly in front of the control handle, which should act as a dead man s handle upon release by the pedestrian in the event of an emergency. The following figures show examples of some of these types of lift trucks. Unit IC Element IC7: Work Equipment (Mobile, Lifting and Access) 7-5

20 Mobile Work Equipment: Hazards and Control Measures Four-directional truck Reach truck Pedestrian pallet stacker Pedestrian counterbalance truck Side loading truck Types of lift truck 7-6 Unit IC Element IC7: Work Equipment (Mobile, Lifting and Access)

21 Mobile Work Equipment: Hazards and Control Measures Agricultural Tractors Agricultural tractors are used for pulling machinery or trailers for activities such as ploughing, tilling, discing, harrowing, planting, and similar tasks. Works Vehicles Works vehicles include any vehicles that are used in a work setting, such as forklift trucks, compact dumpers, tractors or mobile cranes. They can also include cars, vans and large goods vehicles when these are operating off the public highway. Works vehicle Hazards Associated with Mobile Work Equipment There are a range of general hazards associated with mobile work equipment but it is useful to start with a common workplace example, the lift truck, which provides some specific examples of workplace concerns. Lift truck hazards are associated with the: Truck For electrically operated trucks, there is the danger of production of hydrogen gas whilst charging the batteries, as well as the manual handling implications of changing them. For gas (LPG) operated lift trucks, there is a fire and explosion risk, particularly during the changing of cylinders. Hazards arise from poor maintenance of brakes, steering, tyres, lights, etc. and emission of substances whilst being used, i.e. exhaust gases. Operator Driving too fast and cornering at speed can cause the vehicle to overturn or lose its load. Operation Lift trucks are often used in areas where there is a possibility of pedestrian movement. Impact with people as well as with structures such as walls and racking is a constant hazard. Overloading of lift trucks can lead to loss of control in steering and braking, and unevenly or improperly loaded lift trucks can become unstable. Driving over unsuitable ground can cause the load to shift or fall off. Mobile work equipment, in general, presents the following range of hazards: Rollover Under certain conditions there may be a risk of rollover of mobile work equipment whilst it is travelling, e.g. a moving dumper truck on a construction site or an agricultural tractor manoeuvring on a slope. This can involve rollover onto its side or end (i.e. through 90 degrees) or turning over completely (i.e. through 180 degrees or more). The risk will depend on the: Nature of the mobile work equipment and any attachments or accessories fitted to it. Effects of any work being carried out on or by the mobile work equipment. Conditions in which it is used. Other factors include: Uneven surfaces. Variable or slippery ground conditions. Excessive gradients. Inappropriate speeds. Incorrect tyre pressures. Sudden changes in direction. Inertia transmitted to the mobile work equipment by attachments used with it. Measures that can be taken to stabilise mobile work equipment and reduce the risk of rollover include: Fitting appropriate counterbalance weights. Increasing its track width by fitting additional or wider wheels. Locking moveable parts which could otherwise create instability by moving around when the mobile work equipment is travelling. Unit IC Element IC7: Work Equipment (Mobile, Lifting and Access) 7-7

22 Mobile Work Equipment: Hazards and Control Measures Overturning The vertical mast of a forklift truck (FLT) will prevent an FLT overturning by more than 90 degrees, provided it has sufficient strength and dimensions for this purpose. It will also protect seated operators from being crushed between the FLT and the ground in the event of rollover. However, if risk assessment shows that an FLT with a seated ride-on operator can rollover in use and there is a risk of the operator leaving the operating position and being crushed between the FLT and the ground, a restraining system, such as a seat belt, will be required. To be effective, the restraining system should prevent operators or others carried from falling out or being trapped by the FLT or its protective structure in the event of rollover. TOPIC FOCUS The factors affecting the likelihood of an agricultural tractor overturning are: Gradient. Direction of travel. Uneven or soft ground. Stability of attachments. Wheel width. Tyre pressure or condition. Speed on cornering. Seizure of power take-off shaft. Suitability for Carrying Passengers Mobile work equipment can present a hazard to persons being carried and therefore should be designed to prevent people falling from it and to allow them to stabilise themselves while it is travelling. Operator positions with seats or work platforms will usually provide a secure place that drivers and other people can travel on. Seats provide security for: Drivers who need to be seated when operating mobile work equipment (e.g. the seat on a site dumper). People who need to be seated while being transported by the mobile work equipment (e.g. bench seats in mine locomotive man-riding carriages). People who are involved in on-board work activities which are best carried out in a seated position. Properly designed and constructed cabs, operators stations and work platforms can prevent people from falling from mobile work equipment when it is travelling. They should be provided with suitable side, front and rear barriers or guard rails, and may be fully enclosed or open to the environment. Under exceptional circumstances, mobile work equipment not specifically designed for this purpose will be used to carry people, e.g. trailers used to carry farm workers during harvest time. Under these circumstances, the mobile work equipment must have features to prevent people falling from it and to allow them to stabilise themselves while it is travelling, e.g. sides of appropriate height, secure hand-holds and means to safely mount and dismount. Unauthorised Start-Up Mobile work equipment can be prone to operation by unauthorised or trained persons. This can be prevented by ensuring that the starter key or device is issued or made accessible only to authorised people. This means that access to starter keys and starting devices, such as removable dumper starting handles, should be controlled. Keys should be controlled Overrun of Speed If mobile work equipment suddenly speeds up, sudden movements could put the people being carried at risk. If speed is not controlled, mobile work equipment may become unstable, particularly on cornering or on gradients across which it needs to travel. If work needs to be carried out during the journey, then speeds should be adjusted or limited as necessary. When carrying people, mobile work equipment should be driven within safe speed limits to minimise any risk to persons being carried. 7-8 Unit IC Element IC7: Work Equipment (Mobile, Lifting and Access)

23 Mobile Work Equipment: Hazards and Control Measures Contact with Wheels or Tracks and Falling Objects Operators and other workers travelling on mobile work equipment may be at risk from: The wheels or tracks of the equipment. Falling out of the equipment. Unexpected movement while it is in motion or stopping. Mobile work equipment on tracks There may also be risks associated with the environment and the place in which the mobile work equipment is used, such as falling objects, low roofs and the surfaces on which the equipment operates. Moving Parts/Drive Shafts/Power Take-Offs The power output of mobile work equipment may be sufficient to cause damage to the connected work equipment which could lead to risk, e.g. seizure of the drive shaft could cause the ejection of parts. GLOSSARY DRIVE SHAFT A drive shaft is a device which conveys the power from the mobile work equipment to any work equipment connected to it. In agriculture these devices are known as power take-off shafts. SEIZURE Seizure refers to stalling of the drive shaft as a result of the operating mechanism of any accessory or anything connected to it becoming incapable of movement due to blockage or some other reason. Control measures should be taken, such as: Slip clutches on the power input connection of the connected work equipment to protect it from damage. Guards to protect people from ejection risks in the event of equipment break-up. Safe Operating Station/Platform We have already noted the risks associated with people falling from mobile work equipment, falling objects and contact with wheels or tracks. Consequently it is important to provide a safe operating station or platform on which the drivers and other people can travel. Over-Heating Over-heating or fire due to friction from bearings running hot, electric motors burning out, thermostats failing, or cooling system failures are all risks that might arise during the use of mobile work equipment. Therefore, as we will note later, fire-fighting appliances such as appropriate extinguishers and fire blankets should be provided on the equipment. Energising of Mobile Work Equipment: Hazards As noted earlier, for electrically operated mobile work equipment there is the danger of production of hydrogen gas whilst charging the batteries, as well as the manual handling implications of changing them. For gas (LPG) operated mobile work equipment, there is a fire and explosion risk, particularly during the changing of cylinders. For diesel operated mobile work equipment there is the risk of inhalation of exhaust gases, particularly carbon monoxide, which can accumulate inside closed and inadequately ventilated structures. Hot surfaces on the diesel engine can also constitute a source of ignition if operated in flammable atmospheres. Unit IC Element IC7: Work Equipment (Mobile, Lifting and Access) 7-9